Manitowoc Grove RT9130E-2 SERVICE Manual – PDF DOWNLOAD

Manitowoc Grove RT9130E-2 SERVICE Manual – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove RT9130E-2 SERVICE Manual – PDF DOWNLOAD

Language : English
Pages :366
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Manitowoc Grove RT9130E-2 SERVICE Manual – PDF DOWNLOAD

See end of this Manual for Alphabetical Index 5
SECTION 1 15
Introduction 15
Description 15
Overview of Manuals 15
Delivery Report 16
Customer Support 16
New Owners 16
Safety Information 16
General Crane Design 16
Specific Crane Description 16
Lifting Capacities (Load Chart) 16
Basic Components 16
Axle Weight Distribution 16
List Of Specifications 17
General 17
Dimensions 17
Capacities 17
Torque Converter 17
Transmission 17
Engine 17
Cummins QSL or (QSC) 17
Axles 17
Brakes 17
Wheels and Tires 17
Swing Gearbox 17
Boom 17
Swivel Assembly 17
Hydraulic Pumps 18
Pump #1 18
Pump #2 18
Pump #3 18
Pump #4 18
Hoists 18
Component Location 21
General Maintenance 24
Cleanliness 24
After Cleaning 24
Removal and Installation 24
Disassembly and Assembly 24
Pressing Parts 25
Locking Devices 25
Wires and Cables 25
Shims 25
Hoses and Tubes 25
Inspection 25
Installation 26
Bearings 26
Antifriction Bearings 26
Double Row, Tapered Roller 26
Heating Bearings 26
Installation 26
Preload 26
Sleeve Bearings 26
Gaskets 26
Batteries 26
Hydraulic Systems 27
Cleanliness 27
Keep the System Clean 27
Sealing Elements 27
Hydraulic Lines 27
Visual Inspection of Hoses and Fittings 27
Hydraulic Fittings 29
Flats from Finger Tight (FFFT) Method 29
37° Flared Steel Fitting: Tube or Hose to Fitting 29
Adjustable Straight Thread O-Ring Fittings 29
Nonadjustable Straight Thread O-Ring Fitting: Fitting to Port 30
Electrical System 31
Harnesses, Wires, and Connectors 31
Fatigue of Welded Structures 31
Loctite® 31
Application of Medium Strength Loctite 31
Primer Application 31
Adhesive/Sealant Application 31
Fasteners and Torque Values 32
Torque Wrenches 32
Torque Values 32
Weld Studs 35
Wire Rope 36
General 36
Environmental Conditions 36
Dynamic Shock Loads 36
Lubrication 36
Precautions and Recommendations During Inspection or Replacement 36
Wire Rope Inspection—Running Ropes and Pendant Cables 37
Keeping Records 37
Frequent Inspection 37
Periodic Inspection 38
Wire Rope Inspection—Boom Extension and Retraction Cables 38
Periodic Inspection 38
Wire Rope Inspection/Replacement (All Wire Rope) 38
Seizing Wire Rope 39
Method 1 39
Method 2 39
Installing 35×7 Class Wire Rope 40
Procedures for Cutting and Preparing 35×7 Class Wire Rope 40
SECTION 2 43
Hydraulic System 43
Description 44
Hydraulic Oil Recommendations 44
Draining and Flushing 47
Removing Air from the Hydraulic System 48
Parts Replacement 48
Directional Control Valves 48
Inspection 48
Valve Leakage 48
Binding Spools 49
Visual Inspection of Hoses and Fittings 49
Supply Pressure And Return Circuit 50
Description 50
Hydraulic Reservoir and Filter 50
Pump Distribution 51
Pump No 1 51
Pump No 2 52
Pump No 3 52
Pump No 4 52
Maintenance 52
Troubleshooting 52
Filter Maintenance 54
Filter Element Removal 54
Filter Element Installation 54
Hydraulic Reservoir Removal 56
Hydraulic Reservoir Installation 56
Breather Removal and Replacement 56
Oil Cooler 57
Description 57
Hydraulic Pumps 58
Description 58
Pump No 1 58
Pump No 2 58
Pump No 3 58
Pump No 4 58
Maintenance 58
Pump No 1 Removal 58
Pump No 1 Installation 58
Pump No 2 Removal 58
Pump No 2 Installation 59
No 3 Pump Removal 59
No 3 Pump Installation 59
No 4 Pump Removal 60
No 4 Pump Installation 60
Testing after Repair or Replacement 60
Pressure Setting Procedures 63
Procedure A – For Setting Main Directional Control Valve Relief Pressures 64
Procedure B – For Checking Pressure Reducing/Sequence Valve Setting 66
Procedure for Checking Sequence Valve Setting (see Figure 2-8) 66
Procedure for Checking Controller Supply Pressure Reducing Valve Setting 66
Procedure C – For Checking Swing Brake Supply Pressure 66
Procedure D – For Checking Service Brake and Air Conditioning Circuit Relief Valve Pressure 66
Procedure E – For Checking Service Brake Dual Accumulator Charge Valve Pressure Limits 67
Procedure F – For Checking Accumulator Pre-Charge Pressure 68
Procedure G – For Pre-Charging Accumulator 68
Procedure H – For Checking Front Steer Relief Valve Pressure 68
Procedure I – For Checking Swing Valve Work Port Relief Pressure 69
Procedure J – For Checking Relief Setting for Counterweight Supply Control Valve 69
Procedure K – For Checking Outrigger/Rear Steer Relief Valve Pressure 71
Procedure L – For Checking/Setting the Make-up Oil Manifold (Thermal Contraction) 71
Procedure M – For Checking/Setting the Differential Lock Pressure 72
Procedure N – Checking Charge Air Cooler (CAC) Motor Control Valve – Tier 3 Only 73
Valves 74
General 74
Directional Control Valves 77
Description 77
General 77
Main Directional Valve (Hoist/Telescope/Lift) 77
Swing and Front Steer Directional Valve 77
Counterweight Removal/Cab Tilt Directional Control Valve 77
Maintenance 77
Hoist/Lift/Telescope Directional Valve Removal 77
Hoist/Lift/Telescope Directional Valve Installation 77
Swing/Steer Directional Valve Removal 77
Swing/Steer Directional Valve Installation 77
Counterweight Removal/Cab Tilt Directional Valve Removal 77
Counterweight Removal/Cab Tilt Directional Valve Installation 78
Functional Check (Both Valve Banks) 78
Function Check – RCL Lockout Valves 78
Swing Series Parallel Selector Valve 82
Description 82
Maintenance 82
Removal 82
Installation 82
Pressure Reducing Sequence Valve With Solenoid Controls Manifold 83
Description 83
Maintenance 83
Removal 83
Installation 83
Swing Brake Release Valve-Function Check 83
Crane Function Valve-Function Check 83
Steering Control Valve-Dual Displacement 85
Description 85
Maintenance 85
Removal 85
Installation 85
Charge Air Cooler (CAC) Motor control Valve 86
Description 86
Maintenance 86
Removal 86
Installation 86
Hydraulic Remote Control Valve 88
Single Axis Control Valves 88
Dual Axis Control Valves (Optional) 88
Maintenance 88
Armrest Control Valve Removal 88
Armrest Control Valve Installation 88
Armrest Control Valve Functional Check 88
Telescope Pedal Control Valve Removal 88
Telescope Pedal Control Valve Installation 88
Telescope Pedal Control Valve Functional Check 88
Swing Power Brake Valve 90
Description 90
Maintenance 90
Removal 90
Installation 90
Function Check 90
Double Pilot Operated Check Valve 91
Description 91
Maintenance 91
Removal 91
Repair 91
Installation 91
Tandem Brake Valve w/ Treadle Pedal 92
Description 92
Maintenance 92
Removal 92
Installation 92
Dual Accumulator Charge Valve 93
Description 93
Maintenance 93
Removal 93
Installation 93
Service Brake Hydraulic Accumulator 95
Description 95
Maintenance 95
Removal 95
Installation 95
Servicing 95
Load Sense Hydraulic Accumulator 95
Description 95
Maintenance 95
Removal 95
Installation 95
Servicing 95
Holding Valves 96
Description 96
Maintenance 96
Removal 96
Repair 96
Installation 96
Lower Lift Cylinder Holding Valve 96
Removal 96
Installation 97
Shuttle Valve 97
Description 97
Maintenance 97
Removal 97
Installation 97
Solenoid Valves 98
Description 98
Oil Cooler Motor Control Solenoid Valve 98
Cold Air Charge Fan Control Solenoid Valve 98
Telescope Rod Drain Solenoid Valve 98
Outrigger Boost Solenoid Valve 98
Parking Brake Solenoid Valve 98
Axle Disconnect Solenoid Valve 98
Telescope Two-Stage Relief Solenoid Valve 98
Cross-Axle Differential Lock Solenoid Valve 98
Maintenance 98
Removal 98
Installation 99
Cross Axle Differential Lock Valve 99
Description 99
Maintenance 99
Removal 99
Installation 99
Check Valves 99
Description 99
Maintenance 99
Removal 99
Installation 99
Outrigger/Rear Steer/Outrigger Box Pin Removal Valve100
Description100
Maintenance100
Removal100
Installation100
Functional Check100
Outrigger Control Manifold102
Description102
Maintenance102
Removal102
Inspection102
Installation102
Functional Check102
Pilot Operated Check Valve103
Description103
Maintenance103
Removal103
Installation103
Pressure Bleed-Off Valve104
Description104
Maintenance104
Removal104
Installation104
Axle Oscillation Lockout Valve106
Description106
Maintenance106
Removal106
Installation106
Relief Valve106
Description106
Maintenance106
Removal106
Installation106
Telescope Cylinder Charge Valve Manifold (If Equipped)107
Description107
Checking/Setting the Charge Valve Manifold107
Maintenance107
Removal107
Installation107
Cylinders110
General110
Maintenance110
Surface Protection For Cylinder Rods110
Leakage Check110
Temperature Effects on Hydraulic Cylinders111
Lift Cylinder113
Description113
Maintenance113
Disassembly113
Inspection113
Assembly115
Dual Rod Telescope Cylinder117
Description117
Maintenance117
Disassembly117
Inspection118
Assembly118
Upper Telescope Cylinder121
Description121
Maintenance121
Disassembly121
Inspection121
Assembly121
Axle Oscillation Lockout Cylinder124
Description124
Maintenance124
Disassembly124
Inspection124
Assembly124
Steer Cylinder126
Description126
Maintenance126
Disassembly126
Inspection127
Assembly127
Outrigger Extension Cylinder130
Description130
Maintenance130
Disassembly130
Inspection130
Assembly130
Outrigger Jack Cylinder132
Description132
Maintenance132
Disassembly132
Inspection133
Assembly134
Tilt Cylinder135
Description135
Maintenance135
Disassembly135
Inspection136
Assembly136
Power Pin Cylinder139
Description139
Maintenance139
Disassembly139
Inspection139
Assembly140
Park Brake Cylinder141
Description141
SECTION 3143
Electrical System143
Description143
General143
Alternator143
Batteries144
Fuse Panel144
Relays145
Maintenance148
General148
General Troubleshooting148
Troubleshooting Engine Starting Problems148
Troubleshooting Engine Charging Problems149
Troubleshooting Accessories149
Troubleshooting Swivel-Caused Electrical Problems149
Connector Troubleshooting149
Indicator Lights150
Troubleshooting Crane Components and Accessories152
Alternator Replacement152
Removal152
Installation152
Check152
Starter Replacement152
Removal152
Installation153
Check153
Battery Replacement153
Removal153
Installation153
Relay Panel Component Replacement153
Accessory Relay153
Buzzer Replacement154
Gauge Cluster Replacement154
Removal154
Installation154
Check155
Rocker Switch Replacement155
Removal155
Inspection155
Installation155
Check155
Ignition Switch Replacement155
Removal155
Inspection156
Installation156
Check156
Turn Signal Lever and Transmission Shift Lever Replacement156
Removal156
Installation157
Check157
Windshield Wiper Assembly Replacement159
Removal159
Inspection159
Installation159
Check160
Windshield Washer Assembly Replacement160
Removal160
Inspection160
Installation160
Check160
Skylight Wiper Assembly Replacement160
Removal160
Inspection161
Installation161
Check161
Telescope Cylinder Charge System – Electrical Schematic (If Equipped)161
Tools For Troubleshooting163
Optional Equipment163
Beacon Light163
Boom Mounted Floodlights163
Rear View Mirror163
Air Conditioner163
Cold Weather Operation163
Component Coolant Heater163
Troubleshooting164
Maintenance Instructions164
SECTION 4165
Boom165
Description166
Lattice Extension167
Optional Lattice Extension167
Optional Lattice Extension Inserts167
Boom Control Switches167
Boom Auto/Manual Telescope Mode Switches167
Center Mid/Inner Mid Boom Telescope Sections Select Switch167
Luffing Jib Switches167
Theory of Operation167
Boom Extension167
Boom Retraction168
Rated Capacity Limiter (RCL) System (with Boom Control System)168
General168
Telescoping Control System Description168
Boom Configuration168
Extension/Retraction Modes168
Extension/Retraction Sequence (Automatic Mode)168
Extension Sequence for the Main Boom169
Extension Sequence for the Main Boom with Boom Extensions or Offset Jibs169
Rated Boom Lengths169
Capacities at Intermediate Boom Lengths169
Hydraulic Actuation and Control System170
Electronic Control System171
System Interfaces and Logic171
Boom Maintenance172
Removal172
Boom Disassembly173
Additional Maintenance, Disassembled Boom180
Boom Nose Sheaves181
Removal181
Installation181
Boom Assembly181
Installation185
Functional Check186
Inspection186
Boom Alignment and Servicing186
Cam Operated Check Valve Adjustment187
Guide Block Adjustment187
Boom Extension and Retraction Cables187
Maintenance187
Inspection187
Adjustment188
Telescope Circuit189
Description189
Theory of Operation189
Maintenance190
Removal and Installation192
Disassembly and Assembly192
Hose Reel193
Description193
Maintenance193
Service193
Removal193
Installation193
Hose Reel Alignment195
Lift Circuit197
Description197
Theory of Operation197
Maintenance197
Troubleshooting197
Removal199
Disassembly and Assembly199
Installation199
Boom Removal System204
Description204
Maintenance204
Upper Lift Cylinder Pin and Cylinder Disassembly204
Upper Lift Cylinder Pin and Cylinder Assembly204
Boom Pivot Shafts and Cylinder Disassembly204
Boom Pivot Shafts and Cylinder Assembly204
Bi-Fold Swingaway Boom Extension206
Description206
Identification206
Hookblock206
Description206
Maintenance206
SECTION 5207
Hoist and Counterweight207
Description207
Theory Of Operation207
Maintenance208
Warm-up Procedure208
Troubleshooting209
Removal211
Installation213
Functional Check213
Usage and Inspection213
Preventative Maintenance213
Oil Sampling215
Oil Change215
Gear Oil Sampling and Analysis215
General Guidelines for Iron Contaminant Level215
Brake Test Procedure215
Hoist to Boom Alignment216
Preparation216
Tools Required216
Procedure216
Motor And Brake218
Description218
Maintenance218
Installation218
Idler Drum and Cable Follower219
Description219
Maintenance219
Idler Drum219
Removal and Disassembly219
Cleaning and Inspection219
Assembly and Installation219
Cable Follower219
Removal and Disassembly219
Cleaning and Inspection219
Assembly and Installation219
Complete Assembly220
Removal220
Installation220
Minimum Layer Indicator222
Description222
Maintenance222
Removal222
Installation222
Hoist Drum Rotation Indicator System224
Description224
Maintenance224
General224
Rotation Sensor224
Thumb Thumper Solenoid224
Troubleshooting224
Hoist Rotation Indicator (HRI) Display System225
Pressure Switches225
HRI Display226
HRI Control Module226
Counterweight Removal and Installation227
Counterweight Stand Installation227
Standard and Heavy Counterweight and Auxiliary Hoist Structure228
Removal228
Installation231
Counterweight Stand Removal232
SECTION 6233
Swing System233
Description233
Theory of Operation234
Swing Drive234
Swing Brake234
Maintenance236
Troubleshooting236
Swing Box Assemblies240
Description240
Swing Motor Maintenance240
Removal240
Installation240
Testing240
Swing Brake Assembly Maintenance241
Removal241
Installation241
Testing241
Swing Gearbox Maintenance241
Removal241
Installation241
Servicing242
Normal maintenance should only consist of proper lubrication and a periodic check of mounting bolt torque values Lubrication consists of maintaining the gearbox oil level Oil in a new gearbox should be drained and flushed after approximately 250 ho242
Oil Changing242
Checking Oil Level242
Testing242
Swing Bearing243
Description243
Maintenance243
General243
Torquing Turntable Bolts243
General243
Torque Values243
Tools Required243
Inner Race Torquing243
Outer Race Torquing243
Removal245
Inspection246
Installation246
Testing247
Swivels248
Description248
Hydraulic Swivel250
Description250
Theory of Operation250
Maintenance250
Removal250
Installation251
Two-Port Water Swivel251
Description251
Maintenance251
Removal251
Disassembly251
Cleaning and Inspection252
Assembly252
Installation252
Electrical Swivel252
Description252
Theory of Operation252
Maintenance252
Removal252
Installation253
Preventive Maintenance253
Slew Potentiometer Preliminary Zero Adjustment Procedure254
Slew Potentiometer Adjustment254
Swing Lock Pin255
Description255
Maintenance255
360° Swing Lock Control—Positive Lock Type (Optional)255
Description255
Maintenance255
SECTION 7257
Power Train257
Description257
Maintenance260
Engine Removal260
Engine Installation261
Engine Drive Belts262
Electronic Control System263
Engine Control System Switches and Indicator Lamps263
Engine Diagnostic Test Mode Switch263
The Diagnostic Test Mode Switch is used when servicing the engine’s electronic control system It is a two position on/off rocker switch used to activate the testing mode (fault codes) When the test mode switch is on, and used in conjunction with 263
Diagnostic/Idle Switch263
Exhaust System Cleaning Active/Manual/Inhibit Switch263
Emergency Stop Switch263
Engine Warning Indicator263
Disable Exhaust System Cleaning Indicator263
High Exhaust System Temperature (HEST) Indicator263
Engine Wait To Start Indicator263
Emergency Engine Stop Indicator263
Fuel System263
Description263
Fuel Tank264
Injection Fuel Pump264
Fuel Filter-Water Separator264
Electric Lift Pump264
Maintenance264
Fuel Tank264
Removal264
Installation264
Fuel Filter-Water Separator264
Draining264
Air Intake and Exhaust System268
Description268
Maintenance268
Air Cleaner Checks268
Check for Filter Restriction268
Air Intake Restriction Monitoring (AIRM) Communications System – Tier 4 Only268
Maintenance Fault (FC5576)268
Severe Fault (FC3341)268
Mechanical Service Indicator – Tier 3 Only268
Tier 3 Filter Element Replacement271
Air Cleaner Body271
Tier 4 Filter Element Replacement272
Element Cleaning272
Air Cleaner Body272
Precleaner272
Vacuator Valve272
Duct Work273
Charge-Air Cooler System274
Maintenance274
Crankcase Breather275
Exhaust275
Tier 3275
Removal275
Installation275
Tier 4277
Removal277
Installation277
Water Cooling System279
Description279
Maintenance279
General279
Effects of Cooling System Neglect279
Overheating279
Overcooling279
Antifreeze/Coolant279
Rust Prevention279
Engine Antifreeze/Coolant Fill Level Check Procedure279
Engine Antifreeze/Coolant Fill Procedure279
Antifreeze/Supplemental Coolant Additives Maintenance Summary280
Cooling System Level Check Interval280
SCA Level Check/Coolant Filter Change Interval280
Cleaning280
Pressure Flushing281
Component Inspection281
Radiator/Surge Tank281
Engine Water Jacket281
Water Pump282
Fans and Belts282
Thermostat282
Hoses and Clamps282
Test Equipment282
Antifreeze/Coolant282
Radiator Removal and Installation282
Removal282
Installation282
Drive Train286
Description286
Maintenance286
Drive Lines286
Removal286
Installation286
Lubrication286
Torque Converter287
Description287
Theory of Operation287
Maintenance288
General Information288
Troubleshooting288
Hydraulic Checks288
Troubleshooting Procedures288
Removal289
Installation289
Servicing the Crane after Transmission/Torque Converter Overhaul291
Lubrication291
Type Of Oil291
Capacity291
Check Period291
Normal Drain Period292
Transmission292
Description292
Maintenance292
Removal292
Installation292
Towing or Pushing292
SECTION 8293
Undercarriage293
Axles293
Description293
Maintenance294
Removal294
Cleaning294
Installation294
Wheel Alignment Check Procedure294
Rear Wheels Not Centered Switch Adjustment Procedure295
Wheels and Tires296
Description296
Maintenance296
Mounting Wheel Assemblies296
Steering Systems297
Description297
Front Steering System297
Rear Steering System297
Theory of Operation297
Front Steering System297
Rear Steering System297
Maintenance297
Front Steering System297
Functional Check298
Rear Steering System299
Hydraulic Pumps300
Description300
Front Steer300
Rear Steer300
Front Steering Control Valve300
Description300
Maintenance300
Removal300
Installation300
Integrated Outrigger/Rear Steer Control Valve300
Description300
Maintenance300
Removal300
Installation300
Functional Check301
Steer Cylinders301
Description301
Maintenance301
Removal301
Installation301
Rear Axle Oscillation Lockout System301
Description301
Theory of Operation301
Axle Oscillation Lockout Cylinders303
Description303
Maintenance303
Removal303
Installation303
Axle Oscillation Lockout Valve303
Description303
Maintenance303
Removal303
Installation303
Brake System304
Description304
Service Brakes304
Parking Brake304
Theory of Operation304
Service Brakes304
Parking Brake304
Maintenance305
Troubleshooting305
General305
Bleeding the Brake System306
Service Brakes306
Description306
Maintenance306
Brake Pad Replacement306
Seal Replacement306
Parking Brake308
Description308
Operation308
Maintenance309
Caliper Overhaul and Seal Replacement309
Park Brake Solenoid Valve310
Description310
Maintenance311
Removal311
Installation311
Outrigger Circuit312
Description312
Theory of Operation312
Maintenance312
Outrigger Beam316
Description316
Theory of Operation316
Maintenance316
Extension Cylinder319
Description319
Maintenance320
Outrigger Monitoring System (Optional—Standard in North America)320
Description320
Removal320
Installation321
Jack Cylinder321
Description321
Maintenance321
Outrigger Control Valves322
Description322
SECTION 9323
Lubrication323
Lubricants and Lubrication Intervals323
Standard Lubricants324
Arctic Lubricants and Conditions325
Temperatures Below -9°C (15°F)325
Cold Weather Package and Lubricants325
Surface Protection for Cylinder Rods328
Wire Rope Lubrication328
Lubrication Points329
CraneLUBE329
Cummins Oil Registration List329
Safety329
Steering and Suspension330
Axles332
Drive Train334
Drive Train (continued)336
Turntable338
Cab Tilt340
Outriggers342
Boom344
Boom (continued)347
Boom (continued)349
Hoist351
Hydraulic353
Diesel Exhaust Fluid (DEF)355
Instructions for Accessing Lubrication Points on Boom357
Carwell® Rust Inhibitor358
Protecting Cranes From Rusting358
Cleaning Procedures358
Inspection and Repair359
Application359
Areas of Application359

IMAGES PREVIEW OF THE MANUAL: